Well, I did it! I ordered my .40 commander slide frame and barrel. I can't wait to get it. I will be documenting this build here so hopefully it will have some entertainment value. Bob was very helpful, those guys at Fusion understand customer service. I will start posting pics as soon as the main parts get in.
Rick

So the frame and slide have arrived! fit is great, very smooth and zero slop. I got the frame slide and barrel from Bob, with the ramped barrel fitted. The frame and slide arrived in stainless so I made a few adjustments to my parts orders to have a uniform look. Here are some pics of the frame and slide as they came.
In thefollowing pictures I ball milled the top of the slide, ball cut the sides and beveled the bottom. I then bead blasted it and polished the sides a little to get a feel for how much it is going to take to get it where I want it.

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